Method for weaving a pile fabric

Abstract

The present invention relates to a method for weaving pile fabrics on a face-to-face weaving machine, where, in successive insertion cycles, weft yarns ( 1-12 ) are inserted between binding warp yarns ( 13-16 ) and pile warp yarns ( 17-24 ), so that two backing fabrics ( 30 ), ( 31 ) are woven one above the another, in which groups of at least four weft yarns ( 1-6 ); ( 7-12 ) are inserted in respective openings between repeatedly crossing binding warp yarns ( 13 ), ( 14 ); ( 15 ), ( 16 ), so that each group of weft yarns ( 1-6 ); ( 7-12 ) comprises at least two pairs of weft yarns ( 2,3 ), ( 5,6 ), ( 8,9 ), ( 11,12 ) inserted above one another, and so that pile warp yarns ( 18 ), ( 21 ), ( 24 ) are interlaced in the upper ( 30 ) and in the lower backing fabric ( 31 ) alternately round the weft yarns ( 2 ), ( 5 ), ( 8 ), ( 11 ), situated on the back, of the said pairs in order to form pile burls, preferably according to a two-shot weave; The present invention likewise relates to pile fabric woven according to this method. Such pile fabrics have a good pile retention, an excellent quality of the back and a great flexibility and may be carried out at a high pile density.

1. Method for weaving pile fabrics on a face-to-face weaving machine, where, in successive insertion cycles, weft yarns ( 1 - 12 ) are inserted between binding warp yarns ( 13 - 16 ) and pile warp yarns ( 17 - 24 ), so that two backing fabrics ( 30 ), ( 31 ) are woven one above the another, in which groups of at least four weft yarns ( 1 - 6 ); ( 7 - 12 ) are inserted in respective openings between repeatedly crossing binding warp yarns ( 13 ), ( 14 ); ( 15 ), ( 16 ), and so that pile warp yarns ( 18 ), ( 21 ), ( 24 ) are interlaced over a weft yarn ( 2 ), ( 5 ), ( 8 ), ( 11 ) in the upper ( 30 ) and lower backing fabric ( 31 ) alternately in order to form pile burls, wherein during the successive insertion cycles each time at least two weft yarns ( 1 , 11 , 12 ), ( 2 , 3 , 7 ), ( 4 , 8 , 9 ), ( 5 , 6 , 10 ) are inserted, so that each group of weft yarns ( 1 - 6 ); ( 7 - 12 ) comprises at least two pairs of weft yarns ( 2 , 3 ), ( 5 , 6 ), ( 8 , 9 ), ( 11 , 12 ), being inserted one above the other and in that the pile warp yarns ( 18 ), ( 21 ), ( 24 ) are interlaced each time over the weft yarns ( 2 ), ( 5 ), ( 8 ), ( 11 ) of these pairs, situated on the back. 
   
   
     2. Method according to  claim 1 , wherein during the successive insertion cycles a pair of weft yarns ( 2 , 3 ), ( 5 , 6 ) is inserted for the upper backing fabric ( 30 ) and a pair of weft yarns ( 8 , 9 ), ( 11 , 12 ) for the lower backing fabric ( 31 ). 
   
   
     3. Method according to  claim 1 , wherein the pile warp yarns ( 18 ), ( 21 ), ( 24 ) forming pile are made to form pile burls according to a two-shot weave. 
   
   
     4. Method according to  claim 1 , wherein in each backing fabric ( 30 ), ( 31 ) co-operating binding warp yarns ( 13 ), ( 14 ); ( 15 ), ( 16 ) are provided, which are crossing one another each time after at least four successive insertion cycles. 
   
   
     5. Method according to  claim 1 , wherein in at least one backing fabric ( 30 ), ( 31 ) pile warp yarns ( 17 - 24 ) forming no pile are woven in, and in that the two weft yarns of each pair of weft yarns ( 2 , 3 ), ( 5 , 6 ), ( 8 , 9 ), ( 11 , 12 ) are provided on the back and on the pile face of these pile warp yarns ( 17 - 24 ) forming no pile respectively. 
   
   
     6. Method according to  claim 1 , wherein in at least one backing fabric ( 30 ), ( 31 ) tension warp yarns ( 25 ), ( 26 ) are provided and pile warp yarns ( 17 - 24 ) forming no pile are woven in, and in that the two weft yarns of each pair of weft yarns ( 2 , 3 ), ( 5 , 6 ), ( 8 , 9 ), ( 11 , 12 ) are provided on the back and on the pile face of these pile warp yarns ( 17 - 24 ) forming no pile. 
   
   
     7. Method according to  claim 1 , wherein during the successive insertion cycles each time three weft yarns ( 1 , 11 , 12 ), ( 2 , 3 , 7 ), ( 4 , 8 , 9 ), ( 5 , 6 , 10 ), ( 1 , 11 , 12 ) are inserted and in that two of them ( 2 , 3 ), ( 8 , 9 ) ( 5 , 6 ), ( 11 , 12 ) are inserted in the upper ( 30 ) and in the lower backing fabric ( 31 ) alternately, whereas each time the third weft yarn ( 7 ), ( 4 ), ( 10 ), ( 1 ) is inserted in the other backing fabric. 
   
   
     8. Method according to  claim 1 , wherein during a number of insertion cycles two weft yarns ( 2 , 3 ), ( 11 , 12 ) are inserted, and in that during a number of other insertion cycles three weft yarns ( 4 , 8 , 9 ), ( 5 , 6 , 10 ) are inserted, two of which weft yarns ( 8 , 9 ), ( 5 , 6 ) are inserted in the one backing fabric whereas the third weft yarn ( 4 ), ( 10 ) is inserted in the other backing fabric, so that each group of weft yarns ( 1 - 6 ), ( 7 - 12 ) also comprises at least one third weft yarn ( 1 ), ( 4 ), ( 7 ), ( 10 ). 
   
   
     9. Method according to  claim 1 , wherein the weaving machine comprises weft insertion means, which are provided to insert three weft yarns ( 1 , 11 , 12 ), ( 2 , 3 , 7 ), ( 4 , 8 , 9 ), ( 5 , 6 , 10 ), ( 1 , 11 , 12 ) per insertion cycle, and in that during the insertion cycle in which two warp yarns ( 2 , 3 ), ( 8 , 9 ), ( 5 , 6 ), ( 11 , 12 ) are inserted, either one weft insertion means is disconnected, or no weft yarn is presented to one of the weft insertion means. 
   
   
     10. Method according to  claim 7 , wherein in at least one backing fabric ( 30 ), ( 31 ) pile warp yarns ( 17 - 24 ) forming no pile are woven in, and in that the said third weft yarns ( 7 ), ( 4 ), ( 10 ), ( 1 ) are provided on the back of these interlaced pile warp yarns. 
   
   
     11. Method according to  claim 7 , wherein in at least one backing fabric ( 30 ), ( 31 ) a number of tension warp yarns ( 25 ), ( 26 ) are provided, and in that the said third tension warp yarns ( 7 ), ( 4 ), ( 10 ), ( 1 ) are provided between the tension warp yarns ( 25 ), ( 26 ) on the one hand and the woven in pile warp yarns ( 17 - 24 ) forming no pile on the other hand. 
   
   
     12. Method according to  claim 1 , wherein pile warp yarns ( 17 - 24 ) forming no pile, distributed among the two backing fabrics, are woven in in these backing fabrics. 
   
   
     13. Method according to  claim 1 , wherein in each group of weft yarns ( 1 - 6 ), ( 7 - 12 ) two pairs of weft yarns ( 2 , 3 ), ( 5 , 6 ), ( 8 , 9 ), ( 11 , 12 ), inserted above one another, are provided, and in that the pile warp yarns ( 18 ), ( 21 ), ( 24 ) are interlaced according to a two-shot weave round the weft yarns ( 2 ), ( 5 ), ( 8 ), ( 11 ), situated on the back, of each pair. 
   
   
     14. Pile fabric comprising a backing fabric ( 30 ), ( 31 ) in which groups of weft yarns ( 1 - 6 ), ( 7 - 12 ) are inserted in respective openings between repeatedly crossing binding warp yarns ( 13 ), ( 14 ); ( 15 ), ( 16 ) and pile burls interlaced over a weft yarn ( 2 ), ( 5 ); ( 8 ), ( 11 ), wherein each group of weft yarns ( 1 - 6 ), ( 7 - 12 ) comprises at least two pairs of weft yarns ( 2 , 3 ), ( 5 , 6 ); ( 8 , 9 ), ( 11 , 12 ) inserted one above the other, and in that the pile burls are interlaced over the weft yarns ( 2 ), ( 5 ); ( 8 ), ( 11 ) situated on the back, of these pairs. 
   
   
     15. Pile fabric according to  claim 14 , wherein pile warp yarns ( 17 - 24 ) forming no pile are woven in in the backing fabric ( 30 ), ( 31 ), and in that the two weft yarns of each pair of weft yarns ( 2 , 3 ), ( 5 , 6 ): ( 8 , 9 ), ( 11 , 12 ) are provided on the back and on the pile face of these pile warp yarns ( 17 - 24 ) forming no pile. 
   
   
     16. Pile fabric according to  claim 14  wherein tension warp yarns ( 25 ), ( 26 ) are provided and in that pile warp yarns ( 17 - 24 ) forming no pile are woven in in the backing fabric ( 30 ), ( 31 ), and in that the two weft yarns of each pair of weft yarns ( 2 , 3 ), ( 5 , 6 ); ( 8 , 9 ), ( 11 , 12 ) are running on the back and on the pile face of these tension warp yarns ( 25 ), ( 26 ) and pile warp yarns ( 17 - 24 ) forming no pile respectively. 
   
   
     17. Pile fabric according to  claim 14 , wherein two weft yarns ( 2 , 3 ), ( 5 , 6 ); ( 8 , 9 ), ( 11 , 12 ) inserted above one another and one weft yarn ( 1 ), ( 4 ); ( 7 ), ( 10 ) inserted separately are inserted alternately in the backing fabric ( 30 ), ( 31 ). 
   
   
     18. Pile fabric according to  claim 14 , wherein each group of weft yarns ( 1 - 6 ), ( 7 - 12 ) comprises two pairs of weft yarns ( 2 , 3 ), ( 5 , 6 ); ( 8 , 9 ), ( 11 , 12 ) inserted above one another and one weft yarn ( 1 ), ( 4 ); ( 7 ), ( 10 ) inserted separately. 
   
   
     19. Pile fabric according to  claim 14 , wherein each group of weft yarns comprises two pairs of weft yarns ( 1 - 6 ), ( 7 - 12 ) inserted above one another and two weft yarns ( 1 ), ( 4 ); ( 7 ), ( 10 ) inserted separately. 
   
   
     20. Pile fabric according to  claim 14 , wherein in each group of weft yarns ( 1 - 6 ), ( 7 - 12 ) the number of weft yarns ( 1 ), ( 4 ), ( 7 ), ( 10 ) inserted separately is less than the number of pairs of weft yarns ( 1 - 6 ), ( 7 - 12 ) inserted above one another. 
   
   
     21. Pile fabric according to  claim 14 , wherein pile warp yarns ( 17 - 24 ) forming no pile are woven in in the backing fabric, and in that the said weft yarns ( 1 ), ( 4 ); ( 7 ), ( 10 ) inserted separately are provided on the back of these woven in pile warp yarns ( 17 - 24 ). 
   
   
     22. Pile fabric according to  claim 14 , wherein a number of tension warp yarns ( 25 ), ( 26 ) are provided and pile warp yarns ( 17 - 24 ) forming no pile are woven in in the backing fabric, and in that the said weft yarns ( 1 ), ( 4 ); ( 7 ), ( 10 ) inserted separately are provided between the tension warp yarns ( 25 ), ( 26 ) on the one hand and the pile warp yarns ( 17 - 24 ) forming no pile on the other hand. 
   
   
     23. Pile fabric according to  claim 1 , wherein pile burls are interlaced over the weft yarns ( 2 ), ( 5 ; ( 8 ), ( 11 ) of each pair of weft yarns ( 2 , 3 ), ( 5 , 6 ); ( 8 , 9 ), ( 11 , 12 ) situated on the back.